Nub pattern connector system

ABSTRACT

A nub-pattern or stud-pattern connecting system has at least two like connecting elements with structured surfaces which have a stud-like formation on one or both sides. The studs make a self-adjusting, form-fitting connection between the connecting elements of the stud-pattern connecting system when the connecting elements are pushed together.

The invention is a connector system that serves as an alternative to the universal Velcro systems.

The principle of the Velcro fastener essentially consists of hooks, which can take a variety of shapes (hook, harpoon, T or mushroom) and are attached to a surface which in turn forms part of a textile surface, locking to a superficial loop fabric.

Forms that feature mushroom-shaped elements are also capable of locking not only to loop fabrics but also to surfaces bearing identical structures.

A special variant is the METAKLETT system, which consists of steel straps mounting a hook system that interlocks with an eyelet strip.

The standard systems have at least the following disadvantages:

The delicate hook systems tend to catch fluff, textile fibres etc., which are difficult to remove and do impair the adhesive characteristics.

Especially in the field of medical applications, this creates hygiene problems as the fluff cannot be eliminated even through washing.

The well-known hook system will not only lock to the intended counterpart but also to other pieces of textile.

This makes its use rather bothersome and leads to the gradual deterioration of the affected areas.

The well-known Velcro systems establish an elastic connection, which in the case of textile fasteners does not present a disadvantage. However, since Velcro fasteners are also used to mount abrasive paper to tool trays for example, this will lead to reduced effectiveness and force transmission in these applications. This is particularly apparent with finishing sanders.

When used to attach tools to tool trays, Velcro fasteners are unreliable since vibrations will cause them to separate especially when small areas are concerned.

Velcro fasteners are widely used as joining elements in the clothing and footwear segment. In this field of application, however, the fact that the side carrying the loop fabric tends to become soaked with water and, unlike the otherwise highly weatherproof material, dries very slowly proves unfavourable.

Velcro fasteners are not suited for establishing tight seals. The carrying capacity of Velcro fasteners needs to be determined empirically because the loop fabric or mushroom-shaped structures will engage in a random rather than well-defined manner.

The number of materials suitable for Velcro systems is quite limited. Elastic materials such as rubber and silicone are precluded. With the exception of the METAKLETT system, Velcro fasteners are made of flammable materials.

Aside from the METAKLETT system, which is stamped, the tapes are difficult to manufacture. Injection moulding or pressing techniques are out of the question.

In addition, the well-known METAKLETT system requires the two joining surfaces to be precisely aligned. Simply pressing the surfaces together without prior exact adjustment, as is the case with standard Velcro tape, is not possible.

The METAKLETT system features sharp protruding edges than may cause personal injury.

The purpose of the invention is to overcome the disadvantages of the state of the art and provide a nub grid connector system for use in different fields of application.

The characteristics of the invention described in the patent claim are intended to address these problems.

This solution is based on a nub grid connector system with characteristics as outlined in claim 1.

Essential features of the invention are that the nubs are moulded as bodies of rotation or as threefold or fourfold segmented bodies of rotation and that the bodies of rotation have at least an apex, conical sliding surfaces and undercuts, and are arranged in a rectangular or hexagonal grid at a distance so as to allow the nubs of the parts to be joined to become jammed or snagged in the connecting process.

For this purpose, two surfaces are provided, impressed, or fabricated using other means, with a nubbed or waffle-like texture on one or both sides. When two such elements are pressed together, the structures will lock with each other and become capable of transmitting forces both vertically and horizontally. The connection can be undone by pulling the elements apart, thus warping the material. This means that the inventive connector system can handle tasks, in some cases even better, which have been left preferably to various types of Velcro fasteners until now.

The system is based on the two-dimensional arrangement of slightly undercut bodies of rotation arranged in a rectangular or hexagonal grid. This gives rise to a waffle-like base body with nub-shaped elevations that will interlock in a form-fit manner when two such elements are pressed together.

For the purpose of the invention, the term “waffle-shaped” or “waffle-like” designates a structure reminiscent of the surface of a traditional waffle iron with a regular two-dimensional array of hollow triangular or quadrangular pyramids without floor area 14 but identical dimensions, where all base edges 14.3 of a pyramid pointing upwards 14.1 are connected to one base edge 14.3 of three of our downward-pointing 14.2 pyramids, and at the corners 14.4 are connected to one corner of the base 14.4 of three or four upward-pointing 14.1 pyramids (FIGS. 61/62.)

Contrary to the METAKLETT system for example, this geometry lets the parts self-align when interlocking.

In contrast to similar connector systems, there is no need for a heteromorphic counterpart, as is the case with Velcro tape and loop tape or lug tape and eyelet tape.

Dependent claims 2 to 30 describe other beneficial properties of the invention according to claim 1, however without restricting them in any way.

The bodies of rotation vary in shape from rounded to sharp-edged, subject to the specific requirements. FIG. 1 shows the range of basic forms. The bodies of rotation are created from the basic form by segmenting, again depending on the requirements, either as a pure body of rotation 2.8 (FIGS. 2 to 4), in a threefold manner 2.9 (FIGS. 5 to 10) or in a fourfold manner 2.10 (FIGS. 11 to 13).As depicted in FIGS. 7, 10 and 13, the upper part 2.5 of the segmented basic bodies 2.9 and 2.10 is trimmed into a hexagonal or octagonal shape 2.7.

Giving rise to the following basic forms:

FIGS. 14 to 19:

A nub-shaped basic form “A”, to be arranged in a rectangular or 10 hexagonal grid, which is particularly well-suited for manufacturing elastic connection elements made of rubbery materials. The edge-free surface allows for easy cleaning.

FIGS. 20 to 26:

A basic form “B” structured along angles of 60°, to be arranged in a hexagonal grid.

By modifying the angles (FIGS. 20, 21), it can be adapted to different requirements of force transmission. The force needed to establish or separate the connection can thus be adjusted, as can the interlocking force of the nubs. Increasing the angle a, for instance, will lead to a higher separating force. If the angle is greater than 90°, the connection will be permanent (FIG. 20). On the other hand, the greater the angle β, the easier it is to establish the connection. A rounding-off 7 of the edge at the origin of angle a will diminish the forces required to establish and separate the connection, providing for outstanding adaptability to material characteristics and fields of application.

Horizontal forces 6 are either transmitted vertically to the load-deflecting surface or will cause the connection to wedge (FIG. 44).

FIGS. 27 to 32:

A basic form “C” structured along angles of less than 90°, to be arranged in a hexagonal grid.

Unlike the basic form depicted in FIGS. 20 to 26, this form allows horizontal forces 6 to be transmitted vertically to the force-transmitting surfaces without interruption (FIG. 46).

Basic form “A” is summarized in FIGS. 33 and 34, basic form “B” in FIGS. 35 and 36, and examples of basic form “C” are given in an isometric representation in FIGS. 37 and 38.

FIG. 39 shows the nubbed surface derived from basic form “A”, FIG. 40 from basic form “B”, and FIG. 31 from basic form “C”, each in top view.

FIGS. 42, 43 (basic form “A), FIGS. 44, 45 (basic form “B”), and FIGS. 46, 47 (basic form “C”) show horizontal sections of the connections. The fitted part 4.3 is shown cross-hatched. The double arrows represent the incoming horizontal forces 6, while the thinner arrows show the distribution of forces for the “A” and “B” variants.

As is clear from the sectional representations, the connection is tight although there are cavities 8 capable of accommodating displaced air and particulate matter, thus allowing two elements to be connected tightly with the help of the invention.

A connection filling the entire space in between the two elements could only be established by working against the resistance of the air being squeezed out completely.

For the purpose of the invention, the term “tight” designates, in particular, the closed state of the connection in which the connecting surfaces are in contact with each other, forming a closed contour and thus a seal.

Depending on the application, nubbed mats may be provided with apertures permitting the air 12 to escape (FIG. 40).

Likewise, any practical application must take into account that the connecting surfaces may harbour particulate matter, which too require cavities to be pushed into when the elements are pressed together.

The inventive connector system be designed to have a smooth underside 4.1/4.2 or with the underside moulded on the analogy of the upside, i.e. as a connecting face 5.1/5.2 (FIGS. 48 to 72).

Such a configuration will result in a system made of homogeneous material which is perfect, amongst other things, for producing cable retainers, self-adhesive insulating elements, etc.

The benefits of the inventive seal (FIGS. 50, 58) and the capability-enhancing cavities 8 (FIGS. 53, 59) are being maintained here too.

Tensile strength of the nub grid tape or nub grid surface is guaranteed by its geometric structure. Tensile loads are transmitted via a rectangular grid 13 (FIG. 57) when utilising the basic form “C”, and via a triangular grid 13 (FIG. 66) of extreme dimensional stability when utilising basic form “B”.

The manufacture of undercut nub types, for instance based on injection moulding, relies on compressible materials.

As for applications that depend on other types of material such as hard plastic or steel sheet, or out of technological necessity, the inventive geometry as shown in FIGS. 63 to 66, can be generated using fitted parts 10 (FIG. 65), which must be placed on the apices 14.1/14.2 (FIGS. 61, 62) of the “waffle-shaped” undercut-free basic body 14 (FIGS. 61, 62).

This technique is also suitable for plain-underside designs.

The variant for creating the inventive geometry (FIGS. 67 to 72) is especially suited to be made of metal.

Here, the undercut required for the connection is generated by bending the stamped straps 11 open. Easily discernible in FIG. 67, the “waffle shape” 14 of the sheet lets the two elements interlock in a self-adjusting manner. FIG. 68 presents a sectional view of the interlocking stamped sheet pieces. Depending on the material thickness and on how far the straps 11 are being bent open, the two elements latch together via the front side of the straps 11 (as shown in FIG. 68) or interlock directly.

In the first case, the connection remains separable while in the second case it is permanent. FIGS. 69 to 71 show an isometric view of possible manufacturing steps (section of the surface). In the first step, the straps 11 are stamped out, followed by the sheet being pressed into a “waffle shape” 14, and the pre-stamped straps 11 bent open in the final step.

In FIG. 72 the straps are shown enlarged.

The invention is a connector system that stands out by ease of manufacture and extraordinary flexibility.

It has some significant advantages over conventional Velcro-based systems: Unless configured as a permanent connection, the inventive system is easy to clean thanks to the shallow undercut. Fluff and other particulate matter cannot be trapped by the nubbed surface. With respect to variants with significant undercut for permanent connection, this aspect is not quite as important since they are expected to be closed only once, meaning that a potential loss of adhesiveness due to fouling is irrelevant.

The fully rounded basic form “A” and flat varieties of the other two basic forms lend themselves to applications governed by strict hygiene standards, for example in healthcare.

Except for the variant as per FIGS. 67 to 72 intended for sheet metal and hard plastic, and to some degree for the permanent-connection variant, the inventive joining system is virtually immune to catching on to other surfaces in an uncontrolled manner. This helps avoiding damage most notably to textile surfaces and does away with the bothersome effect of engaging the wrong surfaces that plagues Velcro fasteners.

With the right choice of materials, angular configuration of the geometry, and selection of rectangular vs. hexagonal grids, the inventive connector system can be adapted to the forces to be absorbed in such a way that both elastic and rigid connections can be created.

This means that, with regard to tools attached to tool trays, the transmission of forces can be made more efficient in comparison with conventional Velcro systems. When employing the inventive system to mount abrasive cloth to a tool tray, which is a very common task, the grinding material cannot detach from the tray without destroying most of the joining nubs, and is practically slippage-free.

Made of rubber-like or synthetic materials, the inventive connector system is well suited for use in weather-exposed pieces of clothing like shoes and weather-proof jackets since it does not absorb any moisture. In addition, it can be used to establish tight seals, which is beyond the capabilities of conventional Velcro fasteners.

The inventive connector system is clearly definable in terms of the forces it can absorb.

Which is especially true with the variant for use with sheet metal (FIGS. 67 to 72) or types derived from the basic form “C”. As a result, the system may also be used to join load-bearing components.

The inventive connector system can be made to any size.

The inventive connector system can fabricated from a variety of materials, allowing for characteristics such as inseparability, resistance to solvents, tensibility, transparency, etc. to be engineered. The inventive connector system is easy to manufacture using injection moulding techniques or, in the variant shown in FIGS. 67 to 72, by stamping out and pressing of homogeneous materials.

The inventive connector system does not require a heteromorphic “counterpart” like the classical Velcro system (fabric hook-and-loop fastener) or in the METAKLETT system (fabric hook-and-eyelet fastener).

Manufactured as “continuous” tape, variants for double-sided use as shown in FIGS. 48 to 72 can be trimmed to any length and employed to join cables, piping etc. or for packaging purposes. In the form of synthetic foam mats, the system can be used in universal protective mats (impact and shock protection) or insulating sheets (sound and heat insulation), which are made even more effective by the air layer trapped between the inner nubs and the material to be insulated and can be joined at the overlapping ends without any auxiliary means.

Using the geometry of the inventive connection, drainage mats designed to seal buildings can perform the function of a walkable nubbed sheet while offering the possibility to be tightly and solidly joined along the edges without the need for additional aids.

The METAKLETT system, compared with the classical Velcro system, has the advantage of being much more robust and resistant to outside influences. The inventive connector system too has these properties, for instance in the variant shown in FIGS. 67 to 72. Moreover, there is no need to accurately align the inventive system before pressing it together, as the two elements will slide over the bevels of the “waffle-shaped” basic body until they reach the locking position.

The METAKLETT system has numerous protruding sharp edges which pose a risk of personal injury.

Being located within “depressions” of the connector system, the protruding straps of the inventive system (variant as per FIGS. 67 to 72), in contrast, present very little danger of injury. With the apices being slightly rounded out, safety is improved while retaining full functionality.

The inventive connector system can be used for joining both identical and different materials, which affords benefits e.g. when mounting a wearing part to a tool tray. The tray can be fitted with a metal connector and the wearing part with a plastic connector. This also permits limiting predetermined breaking points to a single element.

The inventive connector system can be engineered as separable and permanent variants. If the nubs have a pronounced undercut (FIG. 20) or the tongues are bent up more steeply (FIG. 68), the connection, after being established, cannot be undone without destroying the material.

LIST OF REFERENCE SIGNS

-   1. Polygon -   1.1. Polygon, rounded -   2. Nubs -   2.1. Apex (including rounded apex) -   2.2. Upper sliding surface -   2.3. Lower sliding surface -   2.4. Undercut -   2.5. Upper part of body of rotation -   2.6. Lower part of body of rotation -   2.7. Edge to be trimmed of the upper nub element -   2.8. Body of rotation, unsegmented -   2.9. Body of rotation, threefold segmented -   2.10. Body of rotation, fourfold segmented -   2.11. Body of rotation, unsegmented, lower part matched to grid -   2.12. Body of rotation, threefold segmented, lower part of body of     rotation matched to grid -   2.13. Body of rotation, fourfold segmented, lower part of 20 body of     rotation matched to grid -   3. Grid -   3.1. Hexagonal grid -   3.2. Rectangular grid -   4. Connecting element with structure on one side -   4.1. Arranged into hexagonal grid -   4.2. Arranged into rectangular grid -   4.3. Upper part -   4.4. Lower part -   4.5. Nubs of upper part -   4.6. Nubs of lower part -   5. Connecting element with structure on both sides -   5.1. Arranged into hexagonal grid -   5.2. Arranged into rectangular grid -   5.3. Upper part -   5.4. Lower part -   5.5. Nubs of upper part -   5.6. Nubs of lower part -   6. Force transmission vectors -   7. Rounding-off -   8. Cavity -   9. Contact surface -   10. Fitted part -   11. Strap -   12. Air outlet -   13. Grid structure of the horizontally trimmed connecting element -   14. “Waffle-shaped” structure consisting of hollow pyramidal shapes     which are open to the underside -   14.1. Apex top -   14.2. Apex bottom -   14.3. Base edge -   14.4. Base angle -   15. Degree of undercut 

1-40. (canceled)
 41. A nub grid connector system, comprising: at least two corresponding connecting elements with surfaces that have a nubbed structure formed with a plurality of nubs on one or both sides thereof; said nubs being configured, upon being pressed together, to lock into a self-aligning, form-fitting connection between said connecting elements; said nubs being threefold or fourfold segmented bodies of rotation and having at least an apex, conical sliding surfaces, and an undercut; said nubs being disposed in rectangular or hexagonal grids at defined distances causing said nubs of the respective said connecting elements to interlock and become wedged or jammed into one another upon being joined, with individual said nubs merging geometrically in a lower part thereof.
 42. The nub grid connector system according to claim 41, wherein said threefold or fourfold segmented bodies of rotation are formed as a polygon beginning at the apex of each said segmented body, running at an angle a from the apex by a length A down to a right to form a first said sliding surface, then continuing at an angle 11 by a length B downward left, to the left, or upward left, to form said undercut, and finally running at an angle a by a length A down to the right to form a second said sliding surface.
 43. The nub grid connector system according to claim 41, wherein a surface of said threefold segmented bodies of rotation is created by vertical rotation and simultaneous duplication about a vertical axis through a point of origin of a polygon by 360° in three angular steps of 120° each, where each new polygon formed in the process is joined to a respectively preceding polygon by geometric extrusion to create a two-dimensional structure, and edges of an upper portion of said threefold segmented bodies of rotation, formed of a first/upper sliding surface and said undercut, are trimmed radially symmetrically to cause this part of said nubs to assume a hexagonal shape when viewed from above.
 44. The nub grid connector system according to claim 41, wherein a surface of said fourfold segmented bodies of rotation is created by vertical rotation and simultaneous duplication about a vertical axis through a point of origin of a polygon by 360° in four angular steps of 90° each, where each new polygon formed in the process is joined to a respectively preceding polygon by geometric extrusion to create a two-dimensional structure, and the edges of an upper portion of said fourfold segmented bodies of rotation, formed of a first/upper sliding surface and said undercut, are trimmed radially symmetrically to cause this part of said nubs to assume an octagonal shape when viewed from above.
 45. The nub grid connector system according to claim 41, wherein said connecting element is configured with a two-sided functionality with said connecting element having a nubbed structure on an upper face and on a lower face, wherein said nubbed structure of said upper face that is composed of threefold or fourfold segmented bodies of rotation, is duplicated vertically downward with an original surface and a duplicate thereof being kept at a distance at any point, and a solid is geometrically extruded between the two surfaces, designed in such a way that a horizontal section through the mass center of said connecting element will invariably lead to a continuous triangular or rectangular grid, and said bottom face is formed analogously of said upper face, and wherein said bottom face and said upper face constituting separate joining surfaces.
 46. The nub grid connector system according to claim 41, wherein said connecting elements are formed with two-sided functionality and said undercuts of said nubs are fashioned through bent-open straps in continuous sliding surfaces.
 47. The nub grid connector system according to claim 41, wherein said connecting elements are formed, upon being connected, to establish a positive locking form-fit with permanently closing and inseparable connection.
 48. The nub grid connector system according to claim 41, wherein said connecting elements are formed, upon being connected, to establish a positive locking form-fit with a separable connection.
 49. The nub grid connector system according to claim 41, wherein said nubs are formed with homogeneously structured engaging surfaces which, upon being connected, are in full contact with each other across areas of contact, and wherein cavities are formed in between the respective engaging surfaces that are aligned to the grid, spatially segregated, and isolated from one another.
 50. The nub grid connector system according to claim 41, wherein said homogeneously structured surfaces have air outlets formed therein.
 51. The nub grid connector system according to claim 50, wherein said air outlets are located near the foot of said engaging nubs.
 52. The nub grid connector system according to claim 41, wherein said connecting elements are manufactured from materials having a sufficient dimensional stability and resilience and the material is chosen in accordance with requirements of a respective application.
 53. The nub grid connector system according to claim 52, wherein said connecting elements are manufactured from mutually different materials.
 54. The nub grid connector system according to claim 52, wherein said materials of said connecting elements are selected from the group consisting of hard plastic, soft plastic, synthetic foam, rubber, silicone, neoprene, metals and textile materials, homogeneously or as composites.
 55. The nub grid connector system according to claim 54, wherein said connecting elements are composites formed with a basic body carrying a textile cover.
 56. A method for producing a connector system, the method comprising: providing a grid connector system having at least two structurally corresponding connecting elements with surfaces having a nubbed structure with nubs on one or both sides thereof, and wherein the nubs, when the connecting elements are pressed together, lock into a self-aligning, form-fitting connection; engineering the nubs as threefold or fourfold segmented bodies of rotation each having an apex, conical sliding surfaces, and an undercut; arranging the nubs in rectangular or hexagonal grids at such distances that the nubs of the respective connecting elements, when being joined to one another, interlock and become wedged or jammed, and forming the individual nubs with a lower part merging geometrically.
 57. The nub grid connector system according to claim 41, configured as a fastening element for sheet metal and hard plastics, as a system to attach tools to tool trays, as a connection element for pieces of apparel, as a connection element for medical applications and applications that are subject to increased hygiene standards.
 58. The nub grid connector system according to claim 41, configured as a fastening element in tape form.
 59. The nub grid connector system according to claim 41, configured as a fastening element weatherproof clothing and shoes. 